Engineering Capacity May 2019

FOR MANUFACTURERS ABOUT SUBCONTRACTORS

March 2019

INDUSTRY NEWS | TURNED PARTS | HEAT & SURFACE TREATMENTS

FORMING & FABRICATION: Reaching out for quality

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FOR BUYERS OF CONTRACT MANUFACTURING SERVICES Visit our online edition for breaking news, jobs, events, features and searchable directory. www.engineeringcapacity.com Editor: Andy Sandford editor@engineeringcapacity.com Sales Manager: Arfan Qureshi sales@engineeringcapacity.com Tel: 0207 241 4627 Graphic Design: Dave Blake blakey@djbdesign.co.uk Printer: Holbrooks Printers Limited Norway Road, Portsmouth PO3 5HX Engineering Capacity is published six times a year in January, March, May, July, September and November SUBSCRIPTIONS Engineering Capacity is available free of charge to UK buyers and suppliers of subcontract manufacturing services.

For non-qualifying readers, annual subscription rates are as follows for 6 issues posted to addresses in: UK £60.00; Europe £80; Rest of the World £100 You can request your copy and sign up to our free weekly email newsletter on our website or contact us via subscriptions@engineeringcapacity.com www.engineeringcapacity.com Tel: O1737 270 648 Published by: Engineering Capacity Ltd Abbey House, 25 Clarendon Road Redhill, Surrey, RH1 1QZ United Kingdom Registered in England company number 10567217 ISSN 0306-0179 COMING UP IN OUR MAY 2019 ISSUE Laser & Waterjet cutting, Medical, Moulding, Additive Manufacturing, Machined Components, Subcon Preview, Automechanika Preview Please send editorial for consideration to editor@engineeringcapacity.com There is no charge or cost involved with having your editorial included in the magazine or on our website

Editor’s View I don’t know if you saw it, but we ran a fascinating story online recently about how driverless vehicles could bring massively improved independent mobility to blind people.

The story concerns trials that are being carried out by Coventry-based autonomous vehicle specialist Aurrigo in conjunction with Blind Veterans UK. They are looking at how autonomous technology could provide a long-term solution to improve the independence of people that have mobility issues.

Chief Executive of Blind Veterans UK, Major General (Rtd) Nick Caplin CB said: “So many of the blind veterans we support say that not being able to drive is one of the most significant things that hits you when you lose your sight. It’s another way of losing independence and can make people feel more isolated.

“Anything we can do to assist and feedback on this new technology will hopefully benefit the lives of our veterans and the wider disabled community in the years to come.”

Once you start to think about it is quite awe inspiring how this type of technology could transform the lives of people across society.

Isolation can also be a life-changing issue for older people who can no longer drive and who have no ready access to public transport.

Outside London and the major cities it is just not a viable option for most journeys. Driverless cars that could take people with mobility problems where they wanted on demand could bring a completely new dimension to the third age.

We need to ensure though that any solutions are easily understood and usable by people who may have poor eyesight, stiff fingers and aren’t au fait with the latest tech trends. An Uber-like app on a smart phone probably isn’t the answer.

If we get it right the benefits in quality of life and economic activity could be considerable. I hope they are ready before I need one.

Andy Sandford, Editor

Member of the Engineering Industries Association

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Tel: +44 (0)23 9267 7747

MARCH 2019

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Contents March 2019

20 FORMING & FABRICATION

News

Features

06 Making a splash in NZ 06 Grainger and Worral helped

13 Turned Parts 06 Rotec puts the lights out

develop a jet boat engine

All the threes at SRD

20 Forming & Fabrication 06 Non-ferrous facilities added

08 Subcon 2019 opens for registration 06 Sign up now for the UK's

Reaching out for quality

subcontracting show

09 Cobot tooling with carbon fibre 06 Rutland 3D prints robot grippers

10 INDUSTRY NEWS

25 Aerospace & Defence 06 CNC focus on aerospace

10 Midlands Mayor praises A&M 06 Andy Street drops in on

EDM for fir-tree profiles

31 Heat & Surface Treatments 06 Galvanisers charge ahead

EDM specialists

11 Bringing hypercar to a halt 06 Alcon machines brake calipers for hot hybrid

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24 Measurement & Testing Services 06 Keeping corrosion in check

Rapid treatment quotes

21 FORMING & FABRICATION

33 Production Control 06 Supporting growth and expansion MARCH 2019

Engineering Capacity | INDUSTRY NEWS

Composites take on cancer Radiotherapy expert Elektra has chosen TRB lightweight structures as a top supplier for a revolutionary new cancer treatment system.

Elektra’s latest innovation, the Elektra Unity, combines real time magnetic resonance imaging (MRI) with a radiotherapy beam produced using a linear accelerator (LINAC).

Elektra says that this combination of technologies enables you to see and track the target, including changes in tumour position, shape and biology, and provides the real-time information needed to respond immediately— all while the patient is on the table.

TRB Lightweight Structures will manufacture a lightweight flooring solution which will be used in the rooms, or bunkers, that accommodate Elekta’s Unity MR-linac. The specialty flooring can withstand excessive weight distribution and is hinged to allow access to different parts of the machine.

A leader in precision radiation Leading companies from the aerospace, automotive and capital goods sectors have already registered to visit Subcontratación 19.

The International Fair of Manufacturing Processes and Equipment will be held at the Bilbao Exhibition Centre from 4 to 6 June.

Visitors have already

MARCH 2019

medicine, Elekta is committed to ensuring everyone in the world with cancer has access to – and benefits from – more precise, personalized radiotherapy treatments. Elekta’s latest innovation, Elekta Unity, is the world’s first high-field MR-linac and has the potential to transform how clinicians treat cancer.

Andrew Snow, Technical Sales Manager (Industrial) of TRB Lightweight Structures, commented: “We are absolutely delighted to be working with such an innovative and forward-thinking company and are proud that Elekta

identified our lightweight composite products as a real asset to the manufacturing of its products. We have previously worked with the company as a supplier for their Gamma Knife® radiosurgery system, and to now be selected as a supplier for their Unity MR-linac is excellent. TRB recently attended a supplier day at Elekta’s new UK headquarters in Crawley; it is a most impressive and futuristic building, and the company is clearly investing heavily in its future. We are very proud to be supporting Elekta on this journey.”

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Big names head to Bilbao registered from aerospace companies including Aciturri, Aernnova, ITP and Bombardier.

Capital goods sector visitors include Ampo, ArcelorMittal, Danobat and Soraluce, while the automotive industry is represented

by EvoBus, Mercedes Benz Spain, Iveco Spain, Volkswagen-Seat and

Gestamp with Gamesa representing energy.

Subcontratación is co-located with six other trade fairs covering additive manufacturing, digital technologies, used machinery, industrial tools, maintenance and pumps and valves.

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INDUSTRY NEWS | Engineering Capacity Grainger & Worrall (G&W) used advanced casting technology to help NZ firm HamiltonJet Global develop the next generation of marine waterjet propulsion systems.

The new HTX30 waterjet is the result of intense hydrodynamic research, design, and product testing to deliver class-leading waterjet thrust and efficiency for use in patrol and commercial workboats with engines of up to 570kW power.

To reduce time-to-market, meet customer delivery commitments, and shorten overall product introduction timelines, HamiltonJet partnered with G&W on the production of the first set of (six) production waterjets that were used to launch the new product at the two largest maritime industry trade shows (Seawork and Workboat), and were also installed in the first vessels to use the new product.

The partnership, which spanned from HamiltonJet’s design office in Christchurch, New Zealand, to G&W’s manufacturing facility in Bridgnorth, UK, saw the development of 24 large

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Making a splash in NZ

structural aluminium sand castings comprising an integral part of the propulsion unit.

Working closely with HamiltonJet, G&W used cutting edge Magma simulation technology to ascertain casting feasibility and risk. G&W produced mould packs by additive manufacture using its S-max cold cure sand printing system. The result is the development of large structural components cast in marine-grade high silicon alloy in just an eight-week period, since order enquiry.

In addition to challenges

associated with producing unusually large structural castings, G&W also had to ensure its specification and production process matched that of HamiltonJet’s in New Zealand (NZ). This meant matching, as closely as possible, all outputs from the standard production process, including mechanical, thermal and dimensional performance to ensure that the rapid-prototyped product met customer requirements and was fully compatible with future components manufactured in NZ. Key to achieving this was close collaboration at the design for manufacture stage to guarantee right-first-time prototypes.

Richard Reynolds, New Product Introduction Manager at HamiltonJet said, “Our CEO had worked with G&W in a previous role at another company, and with his recommendation we contacted them. G&W’s project and process control met and exceeded our expectations, allowing us to work MARCH 2019

Engineering Capacity | INDUSTRY NEWS an extremely compressed schedule and meet all our deliverables. Central to this was great project management and ongoing clear communication between both teams separated by 12 time zones and 12,000 miles.

Both teams put in the extra effort holding multiple late night / early morning phone conferences to ensure project success.”

Edward Grainger, director of Grainger & Worrall, commented:

“With over 250 new product introductions coming through our business each year, we are familiar with delivering the art of the possible in the shortest lead times. This project was no exception, there were obvious challenges around scale; moulds exceeded 2 tonnes of printing, and casting required an inventive solution to avoid defects with this slow freezing hypereutectic alloy.

Nonetheless, we prospered to

deliver fully machined parts in time for hugely positive show launches and sea trials.

“It is a real privilege to work with a market leading innovative business. It is especially rewarding to know we have contributed to bringing another product line and hopefully becoming part of the continued successful legacy that is HamiltonJet.” 8 gwcast.com

NEW Subcontract precision turned parts now up to 65mm in diameter from bar and 300mm billet work.

CONTACT CONT TAC CT US TODAY TODAY FOR A QUOTE QUOTE

MARCH 2019

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INDUSTRY NEWS | Engineering Capacity Visitor registration in now open for Subcon, the UK's dedicated subcontract manufacturing supply chain show, which runs from 4 to 6 June at the NEC Birmingham.

The show aims to offer the contacts, connections and content UK engineering and manufacturing businesses need to forge new partnerships, drive costs down, improve productivity and tackle the challenges of a tumultuous economy.

Visitors will be able to see over 300 suppliers who will be able to help them increase capacity, optimise productivity and improve flexibility. Exhibitors confirmed so far include Faro, Lucy Castings, UKF Group, Grenville Engineering, Metpro and Continental Automotive.

New for 2019, visitors will discover the industry superstars of tomorrow in the brand-new Subcon Launchpad and Launchpad Awards. This will feature eight of the UK’s most innovative engineering and manufacturing start-ups, each of whom will receive a free stand at the show and be entered into the inaugural Launchpad Award.

This year Subcon is co-located d

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Subcon 2019 opens for registration

with The Engineer Expo and the Advanced Manufacturing Show, which will feature on-stand demonstrations of the latest manufacturing and design products.

The Engineer Conference – which runs alongside all three events – will deliver insight on industry issues, with presentations

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Manufacturers of High Quality Mill-Turned Parts

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from industry leaders responsible for some of the UK’s most inspiring and ground-breaking engineering and manufacturing projects.

“This year, amidst challenging economic headwinds, we are dedicated to helping UK engineering and manufacturing businesses harness innovation, forge new partnerships and shape their future business strategies,” said Subcon event director Gordon Kirk.

“From the industry-leading programme of The Engineer Conference to the demonstrations within the Advanced Manufacturing Show and the manufacturing supply chain community that is Subcon, this is all aimed towards one thing – realising business success sooner.”

8 subconshow.co.uk MARCH 2019

Engineering Capacity | INDUSTRY NEWS Injection moulding specialist Rutland Plastics is using tough carbon fibre filled Nylon to 3D print tooling for collaborative robots.

Rutland Plastics, which produces parts for industries such as medical, consumer goods and utilities, has recently sourced a Stratasys Fortus 380mc Carbon Fiber edition from SYS Systems, a UK platinum partner for Stratasys.

The East-Midlands-based business has employed in-house 3D printing since 2012, but its latest upgrade is allowing it to break new ground in collaborative robotics.

The carbon fibre filled material is a light but incredibly tough engineering-grade thermoplastic, giving unparalleled strength for dependable functional prototyping, end-use parts and rugged tooling, often replacing low-volume metal parts.

Simon Grainger, Design and Project Engineering Manager at Rutland Plastics, said: “The Fortus 380CF is ideal as it can print 30% carbon filled Nylon, which is

Cobot tooling with carbon fibre

2018 was a good year for subcontractors with the market up 31% on 2017.

Despite uncertainty for the UK manufacturing industry as a whole, the latest Contract Manufacturing Index (CMI) for 2018 was 227, which compares to a figure of 173 for the previous year.

Within those headline figures though there was a 7% downward trend through the year – although this eased off in the second half.

Busy year for subcontractors

MARCH 2019

excellent for producing end-of-arm tooling because it’s strong and durable but also lightweight, meaning our robots can run faster and we can maximise payload.

“3D printing gives us greater design flexibility. It allows us to design end-of-arm tooling and jigs and fixtures for their specific purpose, and complexity doesn’t increase cost.”

Mr Grainger added: “This is our first introduction into carbon fibre

The CMI for the fourth quarter of 2018 stood at 222 – up 61% on the equivalent quarter in 2017 and fractionally down (0.45%) on the previous quarter of 2018.

Commenting on the figures, Qimtek owner Karl Wigart said: “While Brexit fears may be leading some OEMs to hold off on placing new work, demand for contract

printing, and it’s become massively important to the way that we produce all of our jigs and fixtures, and especially end-of-arm tooling.

“Other benefits include being able to produce functional prototypes which allow us to check fit, function and cosmetics.

“We can incorporate features and mechanisms such as air channels, and we can also use GrabCAD software to pause prints so that we can stop and put components into the actual 3Dprinted parts, such as magnets and sensors, and completely encase them.

“Up until now we’ve never been able to offer low-volume production parts, but the Fortus 380CF allows us to do this to bridge the gap from research and development to production.”

8 rutlandplastics.co.uk

manufacturing is up by 18% since the referendum in 2016.

“There are, though, signs that many subcontractors are now running at or near full capacity because they too are putting off capital investment until the market regains its confidence. If this is not resolved there could be an upward pressure on prices.”

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INDUSTRY NEWS | Engineering Capacity West Midlands Mayor Andy Street praised A&M EDM’s dynamism and commitment as he commissioned equipment from a £750k investment.

This investment pushed the company to record sales of ÂŁ6.1m in 2018, a 32 % increase on 2017, and covered CNC machinery and equipment.

Investments included a 5 Axis Hurco CNC machine, two spark eroders, Hitachi handheld analyser for alloy identification and Renishaw laser calibration to enable preventative maintenance of 22 CNC machining centres Funding came in part from a ÂŁ50,000 grant from the Black Country LEP Growing Priority Sectors fund.

The Mayor saw demonstrations of A&M’s CNC machining, quality inspection and spark and wire erosion capabilities which manufacture prototypes, precision components and tooling for

Midlands Mayor praises A&M

aerospace, automotive, Formula 1 and production assembly customers. He also met apprentices at work, discussed skills development and the role of advanced manufacturing and engineering as the dynamo of the West Midlands Industrial Strategy.

Andy Street said: “A&M is a dynamic symbol of the West Midlands Economic Strategy in

!

"

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action, as an advanced manufacturing SME committed to sustained investment in new machinery, process innovation, developing apprentices and skills.

The Mayor was presented with memento of his visit, using A&M’s capabilities in CAD design, turning and CNC milling. Electrodes were wired to cut the lettering and an embossed West Midlands Combined Authority logo was created by spark eroding the shape.

Mark Wingfield, Managing Director of A&M said: “It was a privilege to host the Mayor and discuss the importance of supply chain SMEs to competitive manufacturing in the West Midlands. We achieved record sales over ÂŁ6m in 2018 and will continue investing in our capabilities, skills and apprentices. We value working in partnership with the public sector; the Growing Priority Sectors grant enabled us to accelerate investment and create new engineering jobs.â€?

8 amedm.co.uk MARCH 2019

Engineering Capacity | INDUSTRY NEWS Tamworth-based Alcon Components has purchased a turnkey machining cell to produce lightweight aluminium monobloc brake calipers for a new hybrid electric hypercar.

Supplied by Kingsbury, the cell includes a Hermle C 32 U 5-axis machining centre fed with pallets from an Erowa Robot Easy 250 automated storage and handling system, the cell was delivered in mid-2018 and started producing the calipers immediately, as the job had already been proved out on a nearly identical cell installed in 2016. The only difference is that the latest machine has a greater extended tool capacity than the previous cell.

The hypercar has one brake caliper per wheel, the set of four requiring in excess of 24 hours of machining from solid aluminium billets. The production route comprises four operations: premilling on another vertical machining centre, op 1 on the Hermle C 32 U, transfer back to the other machining centre for simple boring cycles; and finish machining on the C 32 U. Fully

New start for Newburgh The assets and goodwill of Newburgh Precision Engineering, which went into administration in January, have been purchased by a new company, Vector X-Cel Ltd, which is 51% owned by X-Cel Superturn Ltd and 49%

MARCH 2019

Bringing hypercar to a halt

Interpolative 5-axis machining of free-form surfaces accounts for less than 10 per cent of the cycles on the Hermle machine, with 4+1 and 3+2 strategies used wherever possible to maximise production efficiency.

A limited number of road-going hypercars will be produced and a few track-only versions are also planned. Alcon is responsible for the full foundation brake system, pedal box and actuation as well as a number of high precision chassis components.

When the contract has been completed, Alcon will split its ongoing production of calipers for

high-performance road cars, race cars and defence vehicles between the two automated Hermle-Erowa C 32 U cells.

Alcon’s production engineering manager Brian Cutler said: "Brake caliper production is a natural application for 5-axis machining. Compared with 4-axis metal cutting, it is not only faster but also inherently more accurate, as approach angles can be adjusted to allow shorter and hence more rigid toolholders to access awkward areas of the component. We easily hold tolerances down to 13 microns."

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owned by the Newburgh management team.

The team will be led by Andrew Taylor, Chairman and owner of the X-Cel Group.

Andrew Taylor said: “I’m delighted to be involved with Newburgh, they have an unrivalled reputation for engineering expertise and will complement the X-Cel group. We have exciting plans to invest heavily in the business.”

X-Cel Superturn Ltd and Newburgh Precision Ltd are both manufacturers of high precision machined components and assemblies, supplying into a number of industries to include oil & gas, nuclear & defence, power generation, aerospace and construction industries.

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Trade Leads from the EIA

PEOPLE | Engineering Capacity

The following FREE OF CHARGE trade leads for the UK engineering industry are currently appearing on the Trade Board pages of the Engineering Industries Association at www.eia.co.uk Russia - Chassis components A large vehicle original equipment manufacturer is looking for chassis suppliers.

Reference: 32568 Closing Date: 31/03/2019 Greece – Ice detection systems An SME active in the design and manufacturing of opto-electronic sub-systems is offering partnership opportunities regarding a miniaturized ice detection sensor capable of not only detecting the presence of ice in a surface but also to identify its type (glaze, rime, mixed) and measure its thickness.

Reference: JV1251 Closing Date: 24/05/2019

Joao Ferreira has joined LTi Metaltech as Continuous Improvement Lead Engineer. He will scrutinise manufacturing operations in detail to help generate further manufacturing efficiencies. He successfully implemented a continual improvement strategy in his previous role and is experienced in using tools such as Six Sigma.

Alan Fisher has been appointed as membership advisor of the Farnborough Aerospace Consortium (FAC) has appointed Alan Fisher as its membership advisor. With 35 years’ experience in the sector, Alan is working to grow the membership of the UK’s longest established aerospace and defence trade body.

Gemma Allchin has been promoted to HR Director at Sheffield Forgemasters International Ltd. She was previously HR Manager before joining the executive team. She is now focused on delivering a cohesive HR strategy to support the company's five-year business plan and reports directly to the CEO, David Bond.

Terence Watson has been appointed by supply chain consultancy Vendigital to strengthen its team of sector specialists. He joins Vendigital as senior adviser and will give guidance and support to continue the development of the firm’s transport practice, with a particular focus on railways and optimising collaborations.

UK-Swindon: Cryogenic transfer This tender is for the design, manufacture and supply of a cryogenic, vacuum-insulatedtransfer line (approx. 14 m total length), which is suitable to supply liquid methane at 110 K. Reference: 32740 Closing Date: 25/03/2019 Russia - Metal processing A large vehicle manufacturer needs metal processing and advanced engineering equipment.

Reference: 32589 Closing Date: 31/03/2019 For more information please email head.office@eia.co.uk quoting reference number.

Please remember to use due diligence in responding to Trade Leads. Engineering Capacity provides you with the above information in good faith, but is unable to accept any responsibility or legal liability arising from any use of these leads.

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MARCH 2019

Engineering Capacity | TURNED PARTS Five-axis turning and new CADCAM software have reduced setup times and allow ‘lights-out’ production at Evesham-based Rotec.

The company, which supplies components to the aerospace, automotive and oil and gas sectors using advanced fixed and sliding head turning, has just installed a new Nakamura NTRX 300 supplied by the Engineering Technology Group (ETG), building on a long-term relationship with the machine tool supplier.

Paul Butler, Managing Director and owner of Rotec said: “It is a great machine. We’ve been involved with Nakamura for some time and its technology is extremely reliable, very fast and very accurate,” explained “In our endeavour to move forward and expand, we wanted a machine with all of these attributes that we could also programme directly from our CAM programme with full 5-axis turning.

“We found that just focusing on cycle time wasn’t the right way forward for our business. There is often a lot of downtime between jobs, so the whole idea of this investment is to apply the CAM system and the machine flexibility to reduce our set-up times.

“Now, we can set-up complex jobs very quickly and, with a bar feed and auxiliary loader, we can run these challenging parts unmanned and they come off the machine complete.”

ETG, which is the UK’s exclusive supplier of Nakamura technology, worked with Rotec to source a machine that matched its exact MARCH 2019

Rotec puts the lights out

requirements. The NTRX 300 has a milling head combined with twin opposed spindles which made it a very attractive proposition for the work involved.

The challenge was to get all the technology to work seamlessly for the company so that it trusts the machines to run when employees aren’t there. This meant that during the day staff can set-up complex, automotive and F1 parts, whilst during the night they can look at processing parts that, historically, would be milled components.

Mr Butler added: “ETG put forward CIMCO as a possible solution. This software system is networked and can work across multiple machine tool brands, which suits us perfectly. It gives us a very good view of our efficiency and we have it in a pictorial view so we can instantly see how efficient we have been over the last 12 hours, 3 days, 1 month or 2 months. We can also generate reports for our meetings, so we can analyse performance.”

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Visit our website or contact us for a quote or advice

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TURNED PARTS | Engineering Capacity 2018 saw SRD add three new Citizen sliding head (Swiss type) CNC turning centres – the company has trebled in size since 2015 when it moved to new premises.

A 20 mm bar capacity Citizen Cincom L20 Type VII lathe was installed in 2009 and helped the contract machinists to weather the recession. Last year it added two further models for processing similar size stock in March and August, followed by a 32 mm capacity machine in November.

The ten-year-old machine is currently running 24/7 and still holding tolerance well.

Precision is key for SRD as 60% of the company's business comes from Formula One, with most of the remainder received from customers in the aerospace and electronics sectors. Dimensional and concentricity tolerances down to 6 microns are held on some 50 to 60 mm long, 3 mm diameter components, for example.

To help achieve this level of accuracy reliably, even during unmanned running, all of the latest sliding-head lathes are

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All the threes at SRD

equipped with Citizen's LFV (low frequency vibration) functionality.

The patented system allows stringy swarf generated when machining aluminium, stainless steel, nickel alloys, copper and plastics to be broken into shorter chips, the length of which can be controlled by the cutting program.

Mark Bonham, joint managing director with his brother Paul of the 30 years established, family

owned precision machinists commented, "We had no hesitation in choosing the LFV option on the new Citizen lathes, as being a subcontractor, we have to process a broad variety of materials.

"Often they are not short chipping and it is difficult to break the swarf using chip-breaker geometry on the cutting tool and/or high-pressure coolant.

"With LFV, which acts in two CNC axes simultaneously and is part of the control's operating system, as distinct from a macro in the part program, it is possible to regulate chip size closely without compromising the life of the cutters - in fact, they tend to last longer and break less often."

The impetus last March for installing a 7-axis Cincom L20 Type XII LFV with a Y-axis on the counter spindle and a 135-degree B-axis spindle integrated into the gang tool block for both front and MARCH 2019

Engineering Capacity | TURNED PARTS back machining was down to the original Swiss-type lathe being fully occupied, while enquiries kept coming in for large volume runs of typically 10,000-off per month. One of the contracts won involves producing a two-part, press-fit assembly with a threaded insert that forms a stainless steel oil restrictor used in the aerospace industry.

The machine is more or less devoted to this ongoing job, so a Cincom L20 Type VIII LFV was

purchased on spec five months later and was immediately busy producing diverse parts for a

number of existing and new customers.

The Bonham brothers and their father Steve, who is still active in the business, reckon that, as a rule of thumb, a Swiss-type lathe costs around twice that of a fixedhead machine, but the former is able to produce twice as many parts, allowing a subcontractor to invoice around double the amount per month per machine compared with fixed-head capacity.

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Wealdpark Limited Stand number 5126

Subcontract Capacity #.# MILL TURN FACILITIES USING SLIDING AND FIXED HEAD LATHES WITH BAR CAPACITY UP TO MM DIAMETER -IYANO FIXED HEAD LATHES WITH BAR CAPACITY UP TO MM DIAMETER (URCO VERTICAL MACHING CENTRE 03, $ATATRACK MANAGEMENT SOFTWARE

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Company Contact Details Phil Smith, Director, Wealdpark Limited Sutton Road, St. Helens, Merseyside, WA9 3DJ Tel. 01744 22567 / 732083 Fax. 01744 451339 E: sales@wealdpark.co.uk www.wealdpark.co.uk

MARCH 2019

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TURNED PARTS | Engineering Capacity By adopting a servitization model – with 10% of customers buying machining on an hourly rate – MNB Precision Engineering is in a strong position to benefit from an upturn in oil and gas.

Since taking the reins of the business in 2012, brothers Luke and Elliot Benton have helped MNB Precision to come back from the brink through a focused business strategy.

In 2014, MNB Precision began working with Aston University’s Advanced Services Group on its servitization programme. The manufacturer brought previously outsourced services in-house, offering customers a complete end-to-end engineering precision service that significantly reduces customer costs and lead times.

This included adding a series of Non-Destructive Testing (NDT) techniques, including liquid dye penetration, and magnetic particle inspection. The leadership team

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Engineering at your service

has now taken its servitized offer to another level by providing machining by the hour. To date, three customers have converted to paying an hourly rate for MNB Precision’s machining expertise, already accounting for 10% of the manufacturer’s turnover.

The company is now in a strong position to take advantage of an upturn in oil and gas, which has resulted in it increasing its staffing from 30 to 101 employees and tripling turnover to £10.5m in just

two years. With an orderbook forecast to hit £18m next year, MNB is providing services to over 40 customers, many of which are OEMs and Tier 1 companies.

In the last year, it has invested £750,000 in new CNC machines to boost productivity and it has now invested a further £500,000 in a CNC turning machine, two CNC milling machines and a heavyduty press, all of which will help increase productivity.

The turning machine will also enable MNB to offer a more varied machining capability with live tooling and Y-axis machining, whilst the fourth machine, a 250-tonne hydraulic press, will allow the company to take on even more complex components and to enter into new markets in the coming months.

MNB Precision Managing Director, Luke Benton, said: “It has been a hell of a journey over the last few years, but precision engineering is in our blood and Elliot and I have been determined to make a success of it. Our focus has been putting customers at the heart of everything we do, understanding their issues and adapting to provide innovative solutions. Many of our competitors have stuck to a production-based model, but our global customers demand new thinking from their supply chain.

We’re not just a company that cuts metal but a partner in providing precision engineered parts and services and that’s what’s given us our competitive edge.”

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Engineering Capacity | TURNED PARTS WES Engineering Solutions, a Cornwall based precision engineering manufacturer specialising in tooling for the automotive industry is showing its confidence with a £200k investment in mill-turning capacity.

Launching into 2019, financing a £200k machinery investment in a period when the headlines are discussing challenging finances and a slowing of the UK’s economic growth, indicates WES’s success, commitment to their local workforce and UK manufacturing.

Daniel Hutchings, Group Operations Manager at WES says: “As key suppliers to the automotive industry, including Jaguar Land Rover, we know, more than most, the impact of today’s challenging climate. We are in a unique environment and yet our investment not only boosts our machining capabilities but is also an investment in skills.

Growing world-class talent through our apprentice scheme Plastic Turned Parts has put the focus on metrology with a new optical system to speed inspection throughput.

A new Keyence IM 7020 Image Dimension Measuring System will help to improve workflow through the quality control department, with its ability to accurately measure width, radius, and height dimensions on a wide range of components quickly, with minimal manual intervention.

The system also automatically records and stores all

MARCH 2019

Cornish engineers show confidence

with new machinery that our early engineers and our very best specialists can both utilise, enables us to deliver complex engineering solutions across every spectrum of industry we supply, as well as delivering new market opportunities.”

The WES hardmetal engineering division specialises in the precision machining of some of the world’s hardest materials working with multi-national organisations within the automotive, aerospace, oil and gas industries.

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Optical system speed throughput measurement data as soon as the part is measured. Traceability and efficiency are maintained as inspection reports can be created with a simple push of a button on the system’s interface.

“The system is incredibly easy to use, it’s almost plug and play,” says Jonathan Newis, Managing Director, Plastic Turned Parts.

“We can program it for volume parts that are likely to repeat or, it is just as straightforward and versatile when measuring

individual parts. As we get busier due to increased production demand, some of which is driven by reshoring by existing and new customers, we foresaw a potential bottleneck in the quality department. The addition of this Keyence IM 7020 system overcomes that issue, while ensuring that we have a detailed log of every component that passes through it.”

8 plasticturnedparts.co.uk

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FORMING & FABRICATION | Engineering Capacity

New investment, new look A £1.1m investment in presses, technical cleaning capability and a new corporate identity is focused on growth at pressings specialist Clamason Industries.

Clamason Industries, which provides a single-source design, development and value-added engineering solution, saw orders hit £30m in 2018 for the first time in its 70-year history and is now setting its sights on a three-year expansion plan.

“We have had huge success in doing things differently and challenging clients to change their thinking around component design,” explained Neil Geoghegan, Managing Director of Clamason Industries.

“Our approach is to start working with customers earlier to see if our ability to design for manufacture and our capability to produce precision parts could solve production bottlenecks. For example, we have enjoyed major success in redesigning aluminium castings to be suitable for the pressing process, saving our clients time and money, with the added benefit of being more environmentally friendly.”

He continued: “Investment in the latest press technology and intelligent tooling means we’ve got dozens of other examples, including how we offered one firm a way of onshoring its component from China.

“Since 2015, we have added £12.5m of revenue and this is just the start. Our facilities in 20

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Kingswinford and Slovakia give us a global footprint that will help us attract more customers, which will contribute to our expansion plans.

“There is still the spectre of Brexit hanging over us and, whilst we would like to see a deal, we are looking at a range of measures that might help us cope with the shortterm upheaval of a ‘no deal’.”

Clamason Industries, which holds IATF 16949 and ISO 13485 quality accreditations for the automotive and medical sectors, employs 290 people across the two plants.

The company operates over 11,000 sq metres of dedicated production space in the UK and Slovakia, offering customers access to a wide range of presses,

starting at 20 tonnes and going up to 300 tonnes, with the largest providing a 3-metre bed.

Significant automation has also been installed to speed up lead times and encourage lights-out manufacturing, whilst investment in new technical cleaning facilities means the company is just as adept supplying parts for insulin pens and dry powder inhalers as they are precise components for car entertainment systems.

Ian Davies, Sales Director at Clamason Industries, continued: “We are looking to the future and wanted a new corporate identity that reflected our growth plans and where we want to go.

“After much deliberation we teamed up with Nutcracker Design, who has done a fantastic job of transforming the brand and developing the ‘C’ icon in a way that showcases our precision capabilities.”

8 clamason.com MARCH 2019

Engineering Capacity | FORMING & FABRICATION Blackhill Engineering, the heavy engineering division of SC Group, has added non-ferrous production facilities at its Exeter based site. The company has also announced that it has been certified to the latest health and safety standard.

The new facilities expand Blackhill’s capability in fabrication and machining for specialist markets and represent the first stage in the development of a high-grade stainless-steel facility.

This forms part of a new facility investment plan totalling 35,000sqft to complement the existing 28,000sqft facility.

Since becoming part of SC Group five years ago Blackhill has benefitted from significant investment in facilities, people and processes. It has expanded its markets into nuclear new build and decommissioning, civil Over the last 12 months, European Springs & Pressings, has invested over £2m in its two Cornish factories with a further £1m invested more recently in a number of new advanced technologies.

A new powder-coating line has been installed in a 700 sq. metre extension, a new heat treatment oven acquired and two high-performance spring-end grinding machines complete the recent purchases.

The new equipment, spread across the Penryn and Redruth factories, has doubled the grinding capabilities in the company’s

MARCH 2019

Non-ferrous facilities added

engineering & construction, space & telecommunications, marine & offshore, oil & gas, renewables and automotive from its origins in quarrying and mineral processing.

The new certification to the ISO 45001 standard is significant for the increasingly large contracts Blackhill has been securing from major companies in the nuclear and construction industries.

Dan Baker, Business Development Manager, Blackhill Engineering, said: “It was a real achievement for the business and has helped keep our people and facilities in a safe environment. The certification of our systems has formalised the hard work and diligence of all our people in the business and helps continue the culture of safety and responsibility we aim for.”

Blackhill has also introduced a rigorous programme of continuous improvement throughout the business and the next target is certification on the company’s Environmental Management System, ISO14001, which is planned to be audited for certification later in 2019.

8 blackhillengineering.co.uk

Spring investment programme industrial sector and expanded the automotive sector grinding facilities by 400%. The new heat treatment oven and powder coating line increases automotive production infrastructure by 200%.

Michael Gibbs, Managing Director of the Cornwall operations concludes: “Developing enhanced manufacturing capabilities through investment in high-tech infrastructure and education, enables us to sustain manufacturing competitiveness.

With a global market place

across multiple industries, it is essential that we maintain our reputation for innovation and manufacturing excellence.

“We’re accelerating our industrial and automotive sector expertise, through operational focus, in direct response to customer demand. Our programme of machinery financing is strategic, reflecting a number of years of record growth and our parent company’s, Lesjofors, global position as an investor in manufacturing.”

8 europeansprings.com

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FORMING & FABRICATION | Engineering Capacity

Fabricators add waterjet Precision fabrication specialist LTi Metaltech has installed a new Ridder waterjet cutting machine at its Abingdon factory.

Complementing existing capabilities, the new waterjet machine provides crucial extra capacity to serve newer growth areas of LTi’s business, in addition to its ongoing cryogenic work for long-time client, Siemens for its MRI machines.

With its twin head cutting capability, a 8m x 4m cutting area and a high-pressure water pump with an increased capacity of 75KW that boosts cutting speeds, the new waterjet cutting machine will allow LTi to significantly ramp up its production.

Having for many years been successful in the healthcare

market, LTi has recently secured contracts in new high growth sectors including energy, science and nuclear – the latest investment will allow the company to increase and consolidate its presence in these markets.

The company says it is the only UK manufacturer of its type with a machine of this size able to cut components.

From design, sampling and technical support to manufacture, Simpson Springs & Pressings Ltd provide the complete service.

Tel: 0118 978 6573 Email: sales@simpsonsprings.co.uk

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2018 was a successful year for LTi, and 2019 looks to be even more exciting says LTi Metaltech’s Technical Director, Edgar Rayner.

He says: “The next 12 months will be crucial for us, but it’s another year we are really looking forward to following the great success we had during 2018 in the energy, science and nuclear markets. The rigorous requirements of these sectors already play to our strengths in areas such as audit compliance and quality assurance. And with this latest investment on board, we will be in an even better position to seize on new market opportunities and grow.”

8 lti-metaltech.com MARCH 2019

Engineering Capacity | FORMING & FABRICATION A 4m long laser scanning arm is helping Goodwin international’s in process checks on large, high specification fabrications.

From large primary circuit reactor components standing at 4 metres in height and 5.5 metres in diameter, to machined and welded assemblies of up to 100,000kg in weight, Goodwin International is able to manufacture a multitude of large, high-specification components. In addition; the company also produces small speciality items such as nonreturn valves with a diameter of 105mm, weighing just 3kg.

Given the problems associated with transporting large heavy workpieces to the company’s static CMM, to ensure that accurate dimensional inspection of components can be undertaken throughout the manufacturing process and to confirm that all components are manufactured to the standards demanded by its customers, the company use a range of advanced FARO portable CMMs with both tactile measurement and scanning capabilities to perform regular inprocess checks.

A growing order book and the increasing need for the scanning and dimensional inspection of large components and comparing them to CAD models, recently prompted Goodwin International to purchase a 4-metre version of FARO’s recently launched QuantumM FaroArm, used in combination with a FAROBlu Laser Line Probe HD (High Definition). The resulting FARO QuantumM ScanArm offers best-in-class scanning capabilities.

MARCH 2019

Reaching out for quality

Goodwin International Quality Control Manager, Mark Woolmer explained. “Our advanced facilities allow us to manufacture components for a wide range of sectors including the nuclear, defence, oil and gas, power generation, aerospace and renewable industries. Our world class manufacturing facility, together with our wide range capabilities, enables us to deliver machined and fabricated components for projects such as new build and retrofit power plants.

“Given the nature of the challenging sectors that we serve, we are able to demonstrate full traceability of our materials and processes and to provide detailed quality reports that are tailored to our client’s and their projects. To ensure that we meet the requirements stipulated to us for each project, meticulous inspection routines are undertaken throughout all stages of manufacture.

“Although we make use of a wide range of advanced inspection and testing equipment, our growing collection of portable FARO CMMs are particularly useful for carrying-out highprecision, in-process dimensional inspection routines.

“Now installed and fully operational, our new FARO QuantumM ScanArm is making an excellent contribution to our crucial inspection operations.

Whereas in the past we needed to make several scanning passes to capture all of the required data related to a large component, the 4-metre FARO QuantumM ScanArm with FAROBlu Laser Line Probe HD is able to complete the same scanning routines in just 1 – 2 passes. In-fact its speed and ease of operation means that, without compromising on accuracy, we have cut our scanning inspection times in half.”

8 goodwininternational.co.uk www.engineeringcapacity.com

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MEASUREMENT & TESTING SERVICES | Engineering Capacity

Keeping corrosion in check Following on from the addition of its fatigue testing facility, William Hughes has added salt spray testing to its range of quality control procedures.

Salt spray or salt fog testing exposes springs and other components to a saline fog environment in order to ascertain the corrosion resistance of the material of which they’re made or the surface coating thereof. A controlled saline situation will show how long it takes for a component to accede to rust or other oxides, if indeed it succumbs at all.

Equipment required for the salt spray chamber comprises the holding tank with its salt solution of between 4 – 6% pH and the salt spray cabinet itself where the salt water solution is atomised using pressurised air. The samples to be tested are then exposed to this extremely corrosive saline fog for the requisite amount of time, On-demand manufacturer Protolabs now offers a detailed measurement and inspection reporting service in addition to its standard inspection process to meet specific customer requirements.

This is the first of a number of secondary services Protolabs is launching to provide additional support for on-demand manufacturing requirements.

Surface treatment and assembly will follow later in the year.

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which can be days or weeks depending on the standard to be achieved. Regular daily tests ensure that temperature and the specific gravity of the salt solution are maintained at a level consistent with ASTM B117, an internationally recognised salt spray standard.

The salt spray test is generally applied to items coated in, for

example, Delta-tone® or KTLBlack. These coatings, used in the aerospace and automotive industries, typically are required to meet specifications which include a number of hours of salt spray testing. The requirements that William Hughes meet range from 48 hours to over 600 hours of salt spray testing.

8 wmhughes.co.uk

On-demand inspection services Stephen Dyson, Protolabs’ Special Operations Manager said: “Our customers really value our rapid manufacturing services for low-volume parts and prototypes, but they now want the benefit of on-demand manufacturing for production parts, which have higher expectations for sampling, measurement and process documentation.”

Mr Dyson continued: “The

marked increase from customers across all industries wanting to take advantage of the speed and flexibility of On-Demand manufacturing brings with it a desire to simplify the supply chain. We are offering Secondary Services to reduce the number of process steps that the customer has to manage, saving time and resources.”

8 protolabs.co.uk

MARCH 2019

Engineering Capacity | AEROSPACE & DEFENCE Reducing weight without compromising on structural integrity is currently top of the wish list of most engineering projects. From automotive to aerospace, weight reductions can reduce fuel consumption and carbon emissions.

In the aerospace industry, hightechnology group, Safran Landing Systems has recently partnered with Aluminium Matrix Composites (AMC) manufacturer, Alvant, on a two-year, £28 m project, titled ‘Large Landing Gear of the Future’ with the aim to reduce landing gear components weight by as much as 30 per cent.

The project will look at how AMCs can challenge traditional materials in the design and manufacture of landing gear assemblies. Current landing gear systems are typically stronger and heavier than necessary, accounting for approximately three per cent of aircraft weight, with a corresponding effect on fuel consumption.

AMCs can be used to engineer durable lightweight components for harsh environments.

Compared to unreinforced metals, AMCs can have higher strength, greater stiffness, lower weight, superior wear resistance, lower coefficients of thermal expansion and superior electrical conductivity. AMCs also offer multiple advantages over polymer fibre reinforced materials, such as carbon composites, these include: higher transverse strength and stiffness, a higher thermal operating range, better wear resistance, superior damage MARCH 2019

Metal composites for aerospace

tolerance, easier repairability and more opportunity to recycle.

One of Alvant’s material technologies, AlXal, is a continuous fibre-based AMC. A £513,000 grant from Innovate UK is enabling Alvant to design, manufacture and test an AlXal brake rod with an expected 30 per cent weight reduction over an equivalent titanium component, while maintaining a comparable strength to steel, reducing fuel burn and noise, while also improving reliability and lowering costs.

A newer development from Alvant, CorXal, is a unique highperformance multi-phase AMC that is similar in concept to a sandwich material but made in a single shot process, providing ultra-high stiffness and a density similar to carbon composite. The company is exploring the applications of this material, working with aerospace and defence companies to incorporate the single piece AMC in the leading edge of aircraft wings, as well as various other brackets and structures.

The wing is subject to huge

changes in temperature, as well as being susceptible to bird and lightning strikes. The existing materials used have been found to be susceptible to bond degradation between the skin and core elements. This can be caused by environmental factors such as temperature, moisture ingress and contamination which can negatively impact on the integrity of the bond. The result has been a tendency to design components with excessive safety factors to compensate for this potential degradation. Due to the one-shot production of CorXal there is no bond interface between the skin and core elements, it has a continuous aluminium matrix throughout providing a closed system. This means parts made from CorXal will not succumb to the environmental conditions, maintaining the necessary structural properties needed, increasing stiffness by up to four times compared to some grades of aluminium, and reducing weight by a target of 40% compared to some steels.

8 alvant.com www.engineeringcapacity.com

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AEROSPACE & DEFENCE | Engineering Capacity Middlesex Aerospace is investing in 5-axis multi-tasking machines and a horizontal machining centre with an expanded tool storage system that will allow 24-hour unmanned operation.

The machines represent a seven-figure investment and will be supplied by Yamazaki Mazak.

Middlesex Aerospace supplies critical components and assemblies to major OEMs throughout the global aerospace market. The Basingstoke-based business currently employs 150 staff, including five apprentices, and the new investment will lead to the creation of further roles within its machining and assembly department.

The new equipment will not only reinforce Middlesex Aerospace’s existing in-house precision machining capabilities, but the increased capacity of the new machines will allow the company to further develop its offering to customers. It will now be able to operate lights-out un-manned manufacturing, 24-hours a day throughout the entire week; dramatically improving production volumes.

Big aerospace spenders

Laurence Foulds, Managing Director at Middlesex Aerospace, comments: “Our latest investment in machinery is one of the company’s most significant to date, and will allow us to support a number of new customers and programmes, as we continue to grow the business.

“Mazak has been our long-term machining partner for two decades. The work we undertake

Aerospace Oil & Gas Nuclear Defence

PRECISION ENGINEERING www.thomas-brown-engineering.co.uk Tel: 01484 548903

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Automotive Electronics Hi Fi

Industrial & High Volume Machining

for our customers places a great demand on our equipment, and we know that Mazak machine tools – as well as the company’s Applications Engineering team – ensure we are able to deliver the incredibly high levels of accuracy and repeatability mandated by the aerospace sector.”

Alan Mucklow, Managing Director UK and Ireland Sales Division at Yamazaki Mazak, adds: “Middlesex Aerospace is a fantastic example of a British business taking the lead in the global supply chain and delivering exceptional results. After many years of working together, we are delighted to be able to help the company take a step closer towards realising its long-term strategic goals, through the purchase of three new state-ofthe-art machining centres.

8 middlesexaerospace.com MARCH 2019

Engineering Capacity | AEROSPACE & DEFENCE Coventry-based aerospace subcontractor Arrowsmith Engineering has installed four new Doosan Lynx lathes and a Doosan DNM machining centre and is examining future automation using collaborative robots.

The new machines are being used to machine a range of complex, high-precision parts for the aerospace sector - specifically aero-engine and aircraft braking system components. The parts are made from a variety of metals, including titanium, Nimonics, nickel-based alloys and magnesium to a high level of accuracy and surface finish requirements.

This significant machine tool investment was made following the completion of an extensive internal and external research programme, undertaken by Arrowsmith in partnership with an NCML (National Manufacturing Competitiveness Levels) Assessor, and separately with Cambridge Judge Business School, to review current performance and help direct future business growth.

Explains Jason Aldridge, Managing Director at Arrowsmith Engineering: “We are part of the global aerospace supply chain and, as such, are competing every day with the very best manufacturing companies in the world. Everything we do is built around supplying our customers with high-quality machined parts…delivered on time and in budget.

“We assess and review our performance continually. If and MARCH 2019

Forward-looking investment programme

where improvements can be made - we make them.”

This commitment to continuous improvement has seen the company make significant improvements and modifications to its facility that have included the creation of completely revamped and discrete production sections dedicated to turning, mill-turning and milling (including 5-axis) machining.

As part of its improvement programme Arrowsmith, in 2018, was selected to pilot the NCML programme and worked with a NCML assessor.

Says Jason Aldridge: “We worked with NCML to help improve our competitiveness and to ensure, in the future, that we were achieving the highest levels of customer satisfaction possible.

“Part of the process involved the NCML Assessor talking directly with our customers and to

ascertain, from them, our strengths as well as areas that could be improved.

“The NCML process was invaluable and identified a number of areas where improvements could (and should) be made,” says Mr Adridge.

In addition to continued strategic investment in advanced machine tools Arrowsmith, as a route to further improve its productivity and operational efficiencies, is investigating how and where automation can be incorporated and integrated into its production processes.

The company is now in advanced discussions with Mills CNC and, in a partnership agreement between both companies, will soon be using Doosan Robotic collaborative robots (cobots) for machine tending operations, in its milling production area.

8 arrowsmitheng.co.uk www.engineeringcapacity.com

27

AEROSPACE & DEFENCE | Engineering Capacity Thomas Brown Engineering is targeting the aerospace sector with its latest CNC machining investment.

Meeting the precision needs of its customers has seen a Huddersfield manufacturer make a number of large investments, including the acquisition of the latest CNC machine technology.

The Huddersfield-based subcontractor, which celebrated its 35th birthday in 2018, has worked with the Engineering Technology Group (ETG) to install a new Hardinge Bridgeport XR1000 to help it capitalise on three recent contract wins for the aerospace sector.

The machine is equipped with a Nikken 4th axis rotary table and a powerful GTW spindle that will allow it to machine the toughest materials.

Tom Brown, who founded the business in 1983 after serving an apprenticeship and working at a local firm, said: “Aerospace is a growing market TWI Ltd is leading a new project that looks set to push the boundaries of additive manufacturing to allow for the printing of larger metallic components such as aircraft landing gear.

As a process, additive manufacturing has traditionally been held back by size, with components tending to be small additional components rather than large primary components and structures.

However, this is set to change

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CNC focus on aerospace

for us following our AS9100 accreditation and this helped us secure three important contracts, which required more capacity and shorter lead times.”

He continued: “We spoke to ETG about our requirements and came up with the XR1000, specifying it with a Nikken 4th axis rotary table to give us the opportunity to produce more complex components.

“It is a decision that is already paying off, with some cycle times reduced by as much as 20%.

This makes a major difference to our productivity.”

ETG also worked with BlumNovotest to fit a TC50 spindle probe and ZX-Speed IR tool setting probe to achieve ‘on-machine’ workpiece inspection/ evaluation and in process tool management.

8 thomas-brown-engineering.co.uk

Pushing additive to the max as TWI and partners, including a number of prominent universities and Airbus, look to use additive manufacturing to build missioncritical, structural, primary elements such as turbine blades.

This involves moving away from powder-bed techniques and towards electron beam and other processes to deposit material for large-scale aerospace components including landing gear parts, wing rib components

or important engine pieces.

Not only will this offer costcutting savings due to a reduction in material wastage, but it has also been shown to allow for faster production times using fewer parts.

To create these larger-scale components, the project is building new additive machines that can work in sizes never seen before.

8 twi-global.com

MARCH 2019

Engineering Capacity | AEROSPACE & DEFENCE A new wire erosion machine at Derby subcontractor Promach 3D is producing fir-tree profiles on special tooling for a critical aerospace application.

The Sodick ALC 400G is its second machine from Sodi-Tech EDM and has been purchased to boost capacity and keep up with customer demand.

Established in 2004 by Matt Fazekas with little more than a three-axis vertical machining centre and a laptop for CADCAM software, Promach 3D has grown into a 12-employee business turning over in excess of £1 million per annum. The company has created a strong niche by focusing on bespoke projects for high-end markets, the principal one being aerospace.

Typically, the parts, tooling and assemblies manufactured by Promach 3D are complex in design, with high tolerance and surface finish demands.

Offering three- and five-axis CNC milling, CNC turning and general toolroom manual machining, the company recently sought to increase its wire EDM capacity. Promach 3D had installed a Sodick AG600L in 2012, but in order to meet the demands of an increasing order book, wanted to add another machine.

“We recently introduced an additional facility in Derby, and decided to invest in a second wire EDM, not just to increase capacity, but to take advantage of the latest technology,” explains Mr Fazekas.

“Our existing wire EDM is six years old and technology has moved on. Although we looked at MARCH 2019

EDM for fir-tree profiles

the whole market, due to the reliability and functionality of our AG600L, we returned to Sodi-Tech EDM. The ALC 400G was the right machine for our requirements, largely thanks to its versatility and high specification. As a subcontract business, we never know what will come through the door tomorrow, so we have to be prepared and continue to offer high-end solutions.”

Having made the decision to purchase the machine at MACH 2018, the subsequent months since installation have seen the ALC 400G hard at work.

“We won an aerospace contract that in the first instance involved liasing with the customer to assist with the design-for-manufacture of stainless steel tooling that helps automate the coating of turbine blades,” explains Mr Fazekas. “From the outset it was clear that, due to the complexity of a key feature, wire EDM was the only way it could be made effectively and efficienty.”

Machining high-precision components and tools has been

the mainstay for Promach 3D since the beginning. As the business has expanded so has the complexity of jobs, with the client list following suit. Promach 3D quotes on projects which other engineering companies tend to avoid, typically due to the challenging nature of the parts and materials to be machined.

The turbine blade root holder, as the part is known, is a case in point. An intricate fir-tree profile is the prominent feature of the tool, which is used to clamp the turbine blade into position at its root end, ready for coating.

As a company, Promach 3D has evolved over the years, from producing one-off jigs and fixtures, to small batch production and anything in between. This trend is predicted to continue, as evidenced by the root holders. The company is currently working its way through batches of 150-off, for three types of root holder, with more variants set to follow.

“We designed a fixture to EDM 20 root holders at a time on our new Sodick ALC 400G, typically running lights-out over a 12-hour cycle time,” says Mr Fazekas.

“The AWT [automatic wire threading] technology of the Sodick machine is excellent, which means we can leave it to run assured of its reliability. If we need to run the machine over a longer unattended period, we can use the Sodick Jumbo wire feeder for a full weekend’s worth.”

8 promach3d.com www.engineeringcapacity.com

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AEROSPACE & DEFENCE | Engineering Capacity

Growth programme payback JJ Churchill of Leicestershire has secured more than £100 million in contracts, increased its headcount by 35% and its export forward order book from under £1 million to more than £37 million after five years on the Sharing in Growth productivity and competitiveness programme.

The Market Bosworth-based company was one of the first aerospace suppliers selected for Sharing in Growth in 2013 when its ambitions were to overcome risks caused by the oil crisis by expanding its aerospace export business. The company now manufactures high precision aerospace gas turbine components as well as high horsepower diesel engine components and assemblies for global customers such as Rolls-Royce, Safran, Cummins and Siemens.

Since then, with support from Sharing in Growth, it has redefined its strategy to focus on people, customers and new business development. As a result, JJ Churchill has increased turnover by almost 30% from 2015/16 and now has plans to hit more than £38 million and add around 20 new jobs by 2020. Consequently, the company has been able to make a £10 million investment in plant and equipment.

The Sharing in Growth programme at JJ Churchill’s represented a £1.1 million 30

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investment from the Regional Growth Fund with the company more than matching that, in time spend on business transformation. Sharing in Growth does not require any cash input from beneficiaries, just a commitment to dedicating time to improvement activities. JJ Churchill is now looking to continue its relationship with Sharing in Growth in order to maintain access to the programme’s unrivalled expertise.

Said executive chairman Andrew Churchill: “Sharing in Growth is an excellent example of the government and engineering working together to make our industry more effective, more efficient and future-proofed. This is increasing opportunity, sales and jobs.

“Working with Sharing in Growth, we have invested in our people, our efficiency and our technology so that we can delight customers by delivering quality products in full, on time and with world-beating competitiveness. Last year we

signed one of our biggest ever long-term agreements worth around £70 million to supply precision machined blades to Rolls-Royce. I don’t think it gets any better than that.”

Examples of practical business transformation made at JJ Churchill include improvements to employee engagement, the visibility of mission, vision and values, business planning, the new product introduction process, supply chain management, cost-reduction, shop floor lay-out, processes and visual management, and staff were trained in Business Improvement Techniques NVQs. Sharing in Growth has now helped aerospace suppliers across the UK secure more than £3.6 billion in contracts. This is equivalent to around 30,000 man years‘ work or securing almost 7,000 high-value jobs. The not-for-profit programme is so successful that it is providing a 60:1 return on public investment.

8 sig-uk.org jjchurchill.com MARCH 2019

Engineering Capacity | HEAT & SURFACE TREATMENTS Following new investment and appointments, one of the UK’s longest-established hot dip galvanizers, is targeting new opportunities in the agricultural, transport infrastructure, street furniture and utilities markets.

Despite a challenging year due to rising zinc costs, Halesfieldbased Corbetts the Galvanizers has managed to make the most of its quality processes and quick lead times to secure a number of new contracts that are making the most of the larger galvanizing kettle it installed in late 2017.

This upgrading of capacity was part of a £400,000 investment project to deepen the kettle and to provide important infrastructure improvements in Plant B. “There has been a lot of discussion about what the next twelve months will bring UK manufacturing and most of it focuses around uncertainty and Brexit,” explained Sophie Boothroyd, Finance Director at Corbetts the Galvanizers.

“We can’t control these factors so our approach is very much about focusing on what we do best and how we can continue to win new business. The capacity is there with the recent investment and the extended management team gives us the skills we need to target new opportunities.

“Our biggest sectors currently are utilities (made up in the most part by cable management product), transport (predominantly RV chassis) and parts for lighting columns and fencing. There’s still lots to go after in these sectors.”

She continued: “The only real MARCH 2019

Galvanisers charge ahead

concern with Brexit is the free movement of people given the vast majority of our staff on the shop floor are Eastern Europeans.

“There haven't been any murmurings yet of mass movement back to their native homeland, but it is certainly something we are keeping an eye on and taking measures to protect our skills.

“One example is the way we are building relationships with local employment agencies, another is looking at a wider catchment area and how we can transport people in from Wolverhampton and surrounding areas.

Corbetts the Galvanizers specialise in hot dip galvanizing, which involves the coating of steel with a layer of zinc by immersing the metal in a bath of molten zinc at temperatures of around 450°c.

When exposed to the atmosphere, the pure zinc reacts with the oxygen to form zinc oxide, a strong material that stops further corrosion in many circumstances, protecting the steel from the elements.

Sophie concluded: “The other big project for 2019 will be our commitment to securing the ISO 9001 accreditation, which will formalise our quality management systems.

“This will help us gain entry into other vertical markets and on high-profile projects that demand this standard as part of their tendering requirements - HS2 being a prime example.”

8 wcorbett.co.uk www.engineeringcapacity.com

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HEAT AND SURFACE TREATMENTS | Engineering Capacity Wallwork Group has extended its rapid online aerospace heat treatment quoting system into commercial heat treatment and also hard coatings and vacuum brazing.

Manual quotations can take up to 48 hours to turn around whereas the online equivalent can be undertaken in a matter of minutes. Each quote form only requests details relevant to the process being considered to ensure both ease and speed of completion. For example, commercial heat treatment asks for material, dimensions, weight and quantity with the option to upload CAD or other drawings.

After choosing the treatment details and testing requirements (a simple single click) there is a field to leave any other information. For each option users are guided on how to provide the information. Partially completed quote requests can be saved for later recall.

Users log in to a secure account area where they can review and manage incomplete, pending and final quotes. Only basic user details are required to create an account. Cleary presented icons show the choice of quotes Preserving the tradition originated by the late Robert Peaslee, a brazing pioneer who invented the first nickel-based brazing filler metal, Wall Colmonoy is offering the next session of the European Modern Furnace Brazing School on 8-10 October 2019.

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www.engineeringcapacity.com

Rapid treatment quotes

grouped conveniently under two headings – Aerospace and Commercial. Heat treatment, aluminium and magnesium processes, hard coatings (TiN CrN TiAIN (Hyperlox) Nitron CA Nitron MC Nitron O Nitron 100 Diamonlith DLC) and vacuum brazing are all covered.

Access to the 24/7 service is available from any internet enabled location and on any type of device including desktop PC, laptop and mobile phone. An extensive FAQ provides further guidance if needed. With over 370 sign-ups, in addition to the UK,

enquiries are being received from France, Portugal, Italy, Germany, Spain and Switzerland. Currently available in English, French, German and Italian, other languages maybe considered in the future versions.

Managing the development of the system, Wallwork’s Charlotte Jackson, commented, “We are a 24/7 business in a 24/7 market place. While complicated quotes will still be manual, the online quoting system gives customers a speedy option for those more straightforward pricing needs.”

8 wallworkht.co.uk

Hands-on brazing school Engineers, technicians, quality managers, production managers, and others will participate in “hands-on” practical applications while learning about brazing technology from leading brazing engineers.

This three-day seminar offers knowledge and practical application on: brazing design, metallurgical aspect, atmospheres and furnaces, materials and quality control.

8 Bit.ly/brazingschool

MARCH 2019

Engineering Capacity | PRODUCTION CONTROL Brown and Holmes has grown and expanded into new business areas supported by PSL Datatrack production control system.

Brown and Holmes's success over recent years has been reflected in its growth which has seen a doubling of production output, an increase in turnover of some 50% and the ongoing development of a global business. This has resulted in the acquisition of additional premises and investment in new machinery and staff.

In 2002, Brown and Holmes of Tamworth became the first precision workholding manufacturer to use PSL Datatrack. Specialising in the design and manufacture of complex, bespoke workholding fixtures and tools, in recent years the company has expanded its business to cover new areas including robotics and more recently 3D printing, building upon the company's manufacturing expertise while embracing new technologies, and it now also offers subcontract machining services.

Steve Smith, General Manager, says, “Proper production control is the key to our successful operation and the adaptability of the PSL Datatrack software, customised to meet our evolving production needs, has been vital over the years.” Brown and Holmes recently updated its processes regarding the KPIs it reviews and, after a site visit from PSL Datatrack to discuss different reporting requirements, a new bespoke report that automatically details the activities of the business on a daily basis was MARCH 2019

Supporting growth and expansion

formulated. This includes the value of orders received, invoicing value, purchase invoicing and the value of orders currently on the system. “The daily availability of these KPIs allows us to have better foresight and planning of the sales, production and accounting functions within our business,” says Steve.

Brown and Holmes now use a wide range of PSL Datatrack modules quotations, works orders, purchase orders, scheduling, Shop Floor Data Collection (SFDC), CRM/Tasks, deliveries and invoicing as well as benefitting from customised management reporting. All production data including inspection and finishing is entered on a daily basis and PSL Datatrack provides accurate end-of-job costing which, together with the cost of purchased items such as material and subcontract operations, ensures that Brown and Holmes are constantly

monitoring production efficiency and estimating procedures.

Full traceability is provided as every job is tied back to a specific works order number, encompassing purchasing, production, assembly, inspection, invoice/credits, delivery notes and conformance certificates.

The software also provides invaluable assistance across the company's robotic, precision engineering and new subcontract engineering business areas. The reports available within the PSL Datatrack system allow Brown and Holmes to separate out the different revenue streams within the business and evaluate the activities within each of them. This allows for the assessment of different elements in detail, to find and address the areas that impact on profitability as well as to promote the actions that have a positive effect.

8 brownandholmes.co.uk/ www.psldatatrack.com www.engineeringcapacity.com

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Qualiturn are a very modern subcontract machining service. We offer CNC precision Turned and Milled components to your specifications and quantities. We work with all sizes of customers, offering the same service to all. Supplying various market sectors across the world.

18 Merchant Drive Mead Lane Industrial Estate Hertford, Hertfordshire SG13 7AY Tel. +44 (0) 1992 584499 www.qualiturn.co.uk

LATHES.CO.UK Lathes.co.uk store.lathes.co.uk - where Manuals, Catalogues Drive Belts Books Accessories & Spares are listed The world’s largest machine tool reference archive. Manuals, Catalogues, Books, Pictures Specifications, Technical Guides Wardlow, Tideswell, Buxton, Derbyshire, SK17 8RP Tel. 01298-871633 (from overseas: +44-1298-871633) from 09:00 to 23:00 UK time www.lathes.co.uk

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www.engineeringcapacity.com

MANAGEMENT SYSTEMS 8

Qualiturn Products Limited

PRECISION ENGINEERING 8

Mini Gears is a subcontract manufacturer of machined components, gears and racks.

Winner of 17 Industry Awards, it has a global customer base, 35,000 sq. ft. facility and over 100 machines.

Top Gear House, Bletchley Road Heaton Mersey Industrial Estate Stockport SK4 3ED Tel: 0161 432 0222 www.minigears.co.uk

PSL Datatrack PSL Datatrack is an affordable, modular production control system.

The software streamlines the entire production process from quotation to invoice encompassing sales orders, purchasing, planning, shop floor, quality, financial and management.

Bridwey Precision Manufacturing Ltd A one stop shop for….

Competitive CNC machining service.

Responsive to customers’ needs & deadlines. Prototype & development parts and assemblies.

Low- to medium-volume production parts and assemblies.

DAWSON PRECISION COMPONENTS Manufacturing precision machined components since 1965 Services include: CNC milling, CNC turning, turn/mill machining, sub contracted services, finishing and project management.

Greenfield Lane, Shaw, Oldham, Lancashire, OL2 8QP Tel: 01706 842311

dpc.co.uk

DKW Precision Engineering Celebrating our 49th year supplying CNC Turned and Milled Components to all Sectors in both UK and Export markets. From 1 off to Volume, 1-450mm diameter turning, 1x1mtr milling, fast turnaround.

Quartremaine Road, Airport Service Estate, Portsmouth PO3 5RD Tel: 023 9267 7747 www.dkwengineering.co.uk

Lily Hill House, Lily Hill Road, Bracknell, Berkshire RG12 2SJ Tel: 08456 345931 www.psldatatrack.com PRECISION ENGINEERING 8

MACHINE TOOL MANUALS 8

CNC PRECISION COMPONENTS 8

Unit 2, Deethe Farm Industrial Est, Cranfield Rd, Woburn Sands, Milton Keynes, Bucks MK17 8UR Tel: 01908 585103 www.jflbroaches.co.uk

Mini Gears (Stockport) Ltd

PRECISION ENGINEERING 8

JFL are broach and broaching specialists with amost 40 years personal experience. We offer a comprehensive broaching service covering keyways, squares, hexagons and special forms.

PRECISION ENGINEERING 8

JFL Broaches and Broaching

MACHINING (5 AXIS) 8

BROACHING 8

DIRECTORY | Engineering Capacity

5 High quality precision machined components 5 Trusted technical support service 5 Complete and bespoke service from conception to completion 5 AS9100D & ISO 9001:2015 approved Oldfield Street, Crosland Moor Huddersfield HD4 5AJ T: 01484 548903 www.thomas-brown-engineering.co.uk

8 Albany Road, Weymouth DT4 9TH Tel: 01305 774 552 www.bridwey.co.uk

MARCH 2019

Subcontract Machining

13 - CNC Sliding Heads up to 1”; 14 CNC Twin Turret Fixed Heads up to 65mm; 5 - Twin Turret Twin Spindle; 5 - Twin Turret with Sub-Spindle and 4 - Twin Turret; 4 - CNC Single Turret Fixed Heads up to 6” Billet.

Centreless Grinding & T/rolling. All materials - Stainless Steel; Nickel Alloys and other exotics a speciality.

Prestwood Place, East Pimbo, Skelmersdale, Lancashire WN8 9QE Tel: 01695 727401 www.kirkhamengineering.co.uk

With more than three decades of experience and dedication in producing the highest quality products, Grenville maintains its position as the leading precision sheet metal fabrication company.

Unit 3 Newfield Industrial Estate, High Street,Tunstall, Stoke-on-Trent ST6 5PD Tel: 01782 577 929 www.grenville-engineering.co.uk

MARCH 2019

AS AS 9100 & ISO 9001 Design & Engineering Support Service

TURNING (CNC) 8 TURNED PARTS 8

Parts Assembly Parts

Grenville Engineering (Stoke-on-Trent) Ltd

Budbrooke Road, Warwick, Warwickshire CV34 5XH Tel: 01926 492889 www.batchflow.co.uk

Precision Turned Turned P Parts arts

Kirkham Engineering Co Ltd

Batchflow Engineering Ltd CNC turning capacity from 2mm200mm using high precision Fixed and Sliding Head CNC Lathes.

Experience in machining a range of materials, from Low to Medium volumes, to customers specifications.

CNC Milled Components

Precision Products (Brighton) Ltd A one-stop-shop for high-quality turned parts Accredited to AS9100 Rev D Unit 2 Brookside Avenue, Rustington, West Sussex BN16 3LF Telephone: +44 (0) 1903 776 171 www.precisonproducts.co.uk

SPRING MAKING 8

SHEET METAL WORKING 8

REPETITION TURNED PARTS 8

Sutton Road, St. Helens Merseyside WA9 3DJ Tel: 01744 22567 www.wealdpark.co.uk

APT Leicester, Leicester, the ar artt of precision precision..

Simpson Springs & Pressings Ltd Precision manufacturers of a wide range of compression tension and torsion springs. Also circlips, wireforms, contacts, antennas and light pressings. Quality approved to BS EN ISO 9001:2000.

Unit 1, Latimer Road Industrial Est, Latimer Road, Wokingham, Berkshire RG41 2YD Tel: 0118 978 6573 www.simpsonsprings.co.uk

WATERJET CUTTING 8

Wealdpark Ltd CNC mill-turn facility using Star sliding head lathes with bar capacity up to 32mm diameter.

Miyano and Doosan fixed head lathes with bar capacity up to 65mm.

Hurco vertical machining centre.

SUBCONTRACT CNC TURNING 8

PRECISION ENGINEERING 8

Engineering Capacity | DIRECTORY

ICEE Comprehensive fabrication facilities offering complete turnkey solution.

Design, Precision Engineering, Sheet Metal Fabrication and Welding.

Prototypes, one off or batch work.

Waterjet Capacity: 4m x 2.25m & dash; materials up to 230mm depth.

Aluminium Alloy Specialists.

20 Arnside Road, Waterlooville, Hampshire PO7 7UP Tel: 023 9223 0604 www.icee.co.uk

www.engineeringcapacity.com

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